Systems and methods for multi-factor diagnosis of exhaust aftertreatment system components

Abstract

Systems and methods for diagnosing an aftertreatment system are provided. The system includes an aftertreatment system having a diesel particulate filter (DPF). The system includes a controller configured to: receive sensor data including pressure change data and flow rate data from a sensor; determine a flow resistance of the DPF and a pressure change value; determine that the flow resistance is less than a flow resistance threshold; determine whether the pressure change value is less than a pressure change value threshold; trigger a first failure warning based on determining that the flow resistance is less than the flow resistance threshold and that the pressure change value is less than the pressure change value threshold; and trigger a second failure warning based on determining that that the flow resistance is less than the flow resistance threshold and that the pressure change value is greater than the pressure change value threshold.

What is claimed is: 
     
       1. A system, comprising:
 an aftertreatment system in exhaust gas receiving communication with an engine, the aftertreatment system comprising a diesel particulate filter (DPF); 
 at least one sensor coupled to the DPF; and 
 a controller configured to:
 receive sensor data from the at least one sensor, the sensor data comprising a pressure change and a flow rate; 
 determine, based on the sensor data, a flow resistance of the DPF and a pressure change value; 
 determine that the flow resistance is less than a flow resistance threshold; 
 determine whether the pressure change value is less than a pressure change value threshold responsive to determining that the flow resistance is less than the flow resistance threshold; 
 trigger a first failure warning based on determining that the flow resistance is less than the flow resistance threshold and that the pressure change value is less than the pressure change value threshold, wherein triggering the first failure warning comprises providing a first notification via an operator input/output device; and 
 trigger a second failure warning based on determining that that the flow resistance is less than the flow resistance threshold and that the pressure change value is greater than the pressure change value threshold, wherein triggering the second failure warning comprises providing a second notification via the operator input/output device. 
 
 
     
     
       2. The system of  claim 1 , wherein determining the pressure change value comprises:
 inputting the sensor data into a regression model; 
 determining a regression equation based on an output of the regression model; and 
 determining a slope of the regression equation, the slope of the regression equation corresponding to the pressure change value. 
 
     
     
       3. The system of  claim 2 , wherein the pressure change value is a pressure change slope. 
     
     
       4. The system of  claim 1 , wherein the flow resistance is compared to the flow resistance threshold within a flow rate interval, the flow rate interval bounded by a minimum flow rate and a maximum flow rate. 
     
     
       5. The system of  claim 1 , wherein the pressure change value is compared to the pressure change value threshold within a flow rate interval, the flow rate interval bounded by a minimum flow rate and a maximum flow rate. 
     
     
       6. The system of  claim 1 , wherein the first failure warning is indicative of a first failure type, the first failure type corresponding to a damaged DPF. 
     
     
       7. The system of  claim 1 , wherein the second failure warning is indicative of a second failure type, the second failure type corresponding to a leaking DPF. 
     
     
       8. A method of diagnosing an aftertreatment system component comprising:
 receiving sensor data from at least one sensor, the sensor data comprising a pressure change and a flow rate associated with a diesel particulate filter (DPF); 
 determining, based on the sensor data, a flow resistance of the DPF and a pressure change value; 
 determining that the flow resistance is less than a flow resistance threshold; 
 determining whether the pressure change value is less than a pressure change value threshold responsive to determining that the flow resistance is less than the flow resistance threshold; 
 triggering a first failure warning based on determining that the flow resistance is less than the flow resistance threshold and that the pressure change value is less than the pressure change value threshold, wherein triggering the first failure warning comprises providing a first notification via an operator input/output device; and 
 triggering a second failure warning based on determining that that the flow resistance is less than the flow resistance threshold and that the pressure change value is greater than the pressure change value threshold, wherein triggering the second failure warning comprises providing a second notification via the operator input/output device. 
 
     
     
       9. The method of  claim 8 , wherein determining the pressure change value comprises:
 inputting the sensor data into a regression model; 
 determining a regression equation based on an output of the regression model; and 
 determining a slope of the regression equation, the slope of the regression equation corresponding to the pressure change value. 
 
     
     
       10. The method of  claim 9 , wherein the pressure change value is a pressure change slope. 
     
     
       11. The method of  claim 8 , wherein the flow resistance is compared to the flow resistance threshold within a flow rate interval, the flow rate interval bounded by a minimum flow rate and a maximum flow rate. 
     
     
       12. The method of  claim 8 , wherein the pressure change value is compared to the pressure change value threshold within a flow rate interval, the flow rate interval bounded by a minimum flow rate and a maximum flow rate. 
     
     
       13. The method of  claim 8 , wherein the first failure warning is indicative of a first failure type, the first failure type corresponding to a damaged DPF. 
     
     
       14. The method of  claim 8 , wherein the second failure warning is indicative of a second failure type, the second failure type corresponding to a leaking DPF. 
     
     
       15. An apparatus for diagnosing an aftertreatment system component of a vehicle, the apparatus comprising:
 one or more processors; and 
 memory storing instructions that, when executed by the one or more processors, cause the one or more processors to:
 receive sensor data from at least one sensor, the sensor data comprising a pressure change and a flow rate associated with a diesel particulate filter (DPF); 
 determine, based on the sensor data, a flow resistance of the DPF and a pressure change value; 
 determine that the flow resistance is less than a flow resistance threshold; 
 determine whether the pressure change value is less than a pressure change value threshold responsive to determining that the flow resistance is less than the flow resistance threshold; 
 trigger a first failure warning based on determining that the flow resistance is less than the flow resistance threshold and that the pressure change value is less than the pressure change value threshold, wherein triggering the first failure warning comprises providing a first notification via an operator input/output device; and 
 trigger a second failure warning based on determining that the flow resistance is less than the flow resistance threshold and that the pressure change value is greater than the pressure change value threshold, wherein triggering the second failure warning comprises providing a second notification via the operator input/output device. 
 
 
     
     
       16. The apparatus of  claim 15 , wherein determining the pressure change value comprises:
 inputting the sensor data into a regression model; 
 determining a regression equation based on an output of the regression model; and 
 determining a slope of the regression equation, the slope of the regression equation corresponding to the pressure change value; 
 wherein the pressure change value is a pressure change slope. 
 
     
     
       17. The apparatus of  claim 15 , wherein the flow resistance is compared to the flow resistance threshold within a flow rate interval, the flow rate interval bounded by a minimum flow rate and a maximum flow rate. 
     
     
       18. The apparatus of  claim 15 , wherein the pressure change value is compared to the pressure change value threshold within a flow rate interval, the flow rate interval bounded by a minimum flow rate and a maximum flow rate. 
     
     
       19. The apparatus of  claim 15 , wherein the first failure warning is indicative of a first failure type, the first failure type corresponding to a damaged DPF. 
     
     
       20. The apparatus of  claim 15 , wherein the second failure warning is indicative of a second failure type, the second failure type corresponding to a leaking DPF.